P7 driver/emitter combination for DIY lantern design

aranyak

Newly Enlightened
Joined
Jan 6, 2008
Messages
6
Location
Mumbai, India
Firstly I want to thank cpf for telling me ALL that I know about LED flashlights! I have purchased a few of them (few more on the way).

I would like to design a basic LED 'lantern' for use during power outages. Since it doesn't need to be particularly aesthetic or rugged, I was planning on mounting one (or more) LEDs on a CPU heatsink and using a battery pack + driver circuit to drive them.
As a prototype (before I cough up the $$ for more expensive parts) I put together a driver (DX SKU 7880) and a Q5 emitter that I had lying around on a heatsink, connected to a single AA NiMH, and it's pretty functional..a design that I can live with, so now I'm figuring out what components to use for the 'real' bright version. I don't know how to upload pics yet, once I do I will upload photos of my prototype 'lantern' (if you can call it that).

I have a spare CPU heatsink which I can use. I am aiming at a runtime of about 4+ hours on high, and planning to use a 6xAA NiMH or 8xAA NiMH (2000mAh each) as the battery pack. My initial thoughts on the components are:

LED: 1xSSC P7 mounted on the heatsink directly with thermal glue. Any tips on where to purchase reasonably priced bright P7s are welcome. Are http://www.dealextreme.com/details.dx/sku.12721 or http://www.dealextreme.com/details.dx/sku.11809 options I can explore?
Since I will be mounting the LED(s) on a heatsink, should I mount the bare emitter or should I purchase one with a star?

Driver - undecided - I don't know yet, I checked out http://www.kaidomain.com/ProductDetails.aspx?ProductId=1866 and http://www.dealextreme.com/details.dx/sku.20330
but I don't know if they are the most suitable ones for the project. Any ideas?

Battery pack: 8x2000 mAH = 16000 mAh
1xP7 driven at 3.0A gives 5.3 hrs. 6xAA gives 4 hrs (is this calculation accurate?) Also any idea if such packs are available or would I need to build one?

I'm want this setup to give out approx 1000 lumens(or more!) so is a single P7 enough or is it possible to drive 2 or even 3 P7s from a single driver? Where can I buy such drivers? Is this the most efficient way to get 1000 lumens from a lantern or should I use multiple Q5s? Is a small 6v lead acid battery suitable for this application?

Any thoughts on the heatsinking? Any help is appreciated!
 

spencer

Enlightened
Joined
Jan 19, 2008
Messages
785
Location
Saskatoon, Canada
Your calculations are a bit wrong. For me it is easier to work in watt hours for batteries.

2000 mAh = 2 Ah

so 1.2V x 2Ah = 2.4 watt hours x batteries = 19.2 watt hours.

A D bin P7 emits only 800 lumen so thats a bit less than what you want but at 2.8A a P7 has a Vf of about 3.75V according to the LED testing thread.

The LED uses 2.8A x 3.75V = 10.5 watts

Take into account driver losses (lets use an optimistic 85%) 10.5 watts / 0.85 = 12.35 watts.

19.2 watt hours / 12.35 watts = 1.55 hours

That is considerably shorter than your 4+ hours and it doesn't give the output you want. Consider using XP-G LEDs. They are more efficient. As for heatsinking you should be fine. I run about 7 watts of old Luxeon LED's (less efficient so more heat) through the smallest computer heatsink I could find and with little air movement I find it to be an acceptable temperature.

A lead acid battery could be considered. They are cheaper but heavier. In a lantern weight shouldn't be an issue.

One think I thought of though is a computer heatsink only has one side to mount on so this light will be pretty directional (not 360 degrees).
 

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